Tower/frame structure and components for same

ABSTRACT

A tower/frame structure of interconnected columns and beams (which may be used in a cooling tower) and novel columns, beams, connection mechanisms and other components are provided. In one embodiment, a column and a beam are constructed of pultruded composite fiber-reinforced plastic (FRP) materials. The beam includes two sidewall extensions or flanges (each having one or more attachment apertures) at one end and which are integral with the beam for connection to the column (having one or more corresponding attachment apertures). The dimension/spacing between the inner walls of the two flanges substantially equals or is slightly larger than the outer dimension of the column. The attachment holes are aligned and a fastener is inserted through the extensions and column for attaching the column and beam. The C-shaped end of the beam substantially conforms to the cross-sectional shape and dimensions of the column. Additional plastic components, such as a firewall and toe/trim member, for use in a cooling tower are also provided.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of prior application Ser. No.12/563,860, filed Sep. 21, 2009 which is a continuation of applicationSer. No. 11/804,711, filed May 18, 2007, now U.S. Pat. No. 7,607,646which is a continuation of prior application Ser. No. 11/216,752, filedon Aug. 31, 2005, now U.S. Pat. No. 7,275,734, and is incorporatedherein by reference, which claims priority under 35 USC 119(e) to U.S.provisional Application Ser. No. 60/609,300, filed on Sep. 13, 2004, andwhich is incorporated herein by reference.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to tower and frame structure andcomponents for building same, and in particular, to a cooling tower andcooling tower/frame structure and components for same.

BACKGROUND

As previously described in U.S. Pat. No. 5,851,446 to Bardo, et al(1998) and U.S. Pat. No. 5,902,522 to Seawell, et al. (1999), of whichsome portions are reproduced hereinafter, cooling towers are used tocool liquid by contact with air. Many cooling towers are of thecounter-flow type, in which the warm liquid is allowed to flowdownwardly through the tower and a counter current flow of air is drawnby various means upward through the falling liquid to cool the liquid.Other designs utilize a cross-flow of air, and forced air systems. Acommon application for liquid cooling towers is for cooling water todissipate waste heat in electrical generating and process plants andindustrial and institutional air-conditioning systems.

Most cooling towers include a tower or frame structure. This structuralassembly is provided to support dead and live loads, including airmoving equipment such as a fan, motor, gearbox, drive shaft or coupling,liquid distribution equipment, such as distribution headers and spraynozzles, and heat transfer surface media such as a fill assembly. Thefill assembly material generally has spaces through which the liquidflows downwardly and the air flows upwardly to provide heat and masstransfer between the liquid and the air. Different types of fillmaterials, e.g., stacked layers of open-celled clay tiles, arecommercially available, depending on the desired design and operatingcharacteristics. This fill material is heavy, and can weigh in excess of50,000 pounds for a conventional size air conditioning cooling tower. Assuch, the tower frame/structure and other structural parts of a coolingtower must not only support the weight of the fill material and othercomponents, but must also resist wind forces or loads and should bedesigned to withstand earthquake loads.

Due to the corrosive nature of the great volumes of air and water drawnthrough such cooling towers, it has been the past practice to eitherassemble such cooling towers of stainless steel or galvanized and coatedmetal, or for larger field assembled towers, to construct such coolingtowers of wood, which is chemically treated under pressure, or concreteat least for the structural parts of the tower, or combination of thesematerials.

Metal structures and parts of cooling towers can be corroded by thelocal atmosphere or the liquid that is being cooled, depending on theactual metal used and the coating material used to protect the metal.Further, such metal towers are usually limited in size and are alsosomewhat expensive, especially in very large applications such as forcooling water from an electric power generating station condenser.Concrete is very durable, but towers made of concrete are expensive andheavy. Many cooling towers are located on roofs of buildings, and theweight of a concrete cooling tower can present building design problems.Plastic parts are resistant to corrosion, but prior plastic partsordinarily would not provide enough strength to support the fillmaterial and the weight of the tower itself.

Wood has been used for the structural parts of cooling towers, but woodalso has its disadvantages. Wood towers may require expensive fireprotection systems. The wood may decay under the constant exposure notonly to the environment, but also to the hot water being cooled in thetower. Wood that has been chemically treated to increase the useful lifemay have environmental disadvantages: the chemical treatment may leachfrom the wood into the water being cooled. Fiber reinforced plastic hasbeen used as a successful design alternative to wood and metal.

Within the last decade or so, prior art solutions began using fiberreinforced plastic beams and columns including those shown in U.S. Pat.No. 5,236,625 to Bardo et al. (1993) and U.S. Pat. No. 5,028,357 toBardo (1991), both of which are incorporated herein by reference. Bothpatents disclose prior art structures for cooling towers. Thus, whilethese prior fiber reinforced plastic tower structures have solved manyof the problems associated with wood and metal cooling tower structures,the solutions to the problem of resistance to lateral loading haveincreased the costs of these units. Both the shear wall and laterallybraced frames can be labor intensive to build, since there are manyparts and many connections to be made. With these prior art solutions,there exist a large number of key structural elements, with more complexmanufacturing and inventorying of parts, increasing the complexity ofconstruction, and therefore the costs.

As such, a need existed for a lower cost cooling tower structure, andfor lower cost cooling tower structures that meet less exacting designcriteria. Further, in those fiber reinforced plastic frame structures atthe time, one difficulty with the joint between the columns and beamswas that when constructed with conventional bolts or screws, the beamsand columns could rotate with respect to each other. When tighterconnections were attempted to be made with conventional bolts or screwsto limit the rotation and provide lateral stability without addingdiagonal bracing, the fiber reinforced plastic material could bedamaged, and the problem worsened as the connecting members mightdegrade the fiber reinforced plastic and enlarge the holes in which theyare received.

Some of the problems of these prior art systems were alleviated orreduced with new fiber reinforced cooling tower systems and methods ofconstruction as described in U.S. Pat. No. 5,851,446 to Bardo, et al.(1998) and U.S. Pat. No. 5,902,522 to Seawell, et al. (1999), both ofwhich are incorporated herein by reference. As described therein, thefiber-reinforced plastic (FRP) beams and columns were connected usingmounting plates and bonding adhesive. As noted in these patents, oneadvantage of this prior art system allows a theoretical increase in thesize of the bays, instead of the standard bay with columns spaced aparta distance of six feet, such bays arguably can be increased to providebays with up to twelve feet between columns. However, the use ofmounting plates and bonding adhesive increases the number of components,time and expense in assembling the structure. Moreover, larger baysconstructed in accordance with prior art structures may be unlikely tomeet the design criteria necessary to support the cooling towercomponents and structures, unless larger, stronger and more costlycomponents are utilized.

Accordingly, there is a need for a cooling tower and tower/framestructure having fewer beams and columns, and fewer overall components,that reduce costs and time to assemble, while meeting the overall designcriteria. Moreover, there is needed a tower and structure that providesfor increased spacing of columns (larger bays) and provides a modulardesign thereby allowing additional bays to be added with minimal or noadditional design efforts. Further needed are specially-designed andnovel columns and beams with predetermined structural shapes, and novelcolumn-beam connections and methods, that provide a structurally strong,simple and easy to assemble tower/frame structure.

SUMMARY

In accordance with one aspect of the present invention, there isprovided a support structure having an elongated column having arectangular cross-sectional shape. The column includes a first sidehaving an outer surface, a second side having an outer surface, a thirdside and a fourth side. At least one aperture or opening extends throughthe column and through the first and second sides of the column. Thestructure further includes an elongated beam having a first end and asecond end, and a first side and a second side with each side extendingbetween the first end and the second end. The beam further includes afirst flange having a first aperture and extending outward from thefirst side of the beam and integrally formed as a portion of the firstside. The first flange is positioned adjacent the outer surface of thefirst side of the column such that the first aperture aligns with theopening in the column. A second flange is provided having a secondaperture and extending outward from the second side of the beam andintegrally formed as a portion of the second side. The second flange ispositioned adjacent the outer surface of the second side of the columnsuch that the second aperture aligns with the opening in the column. Afastener extends through each of the first aperture, the second apertureand the opening in the column and operable for coupling the beam to thecolumn.

In another embodiment, there is provided an elongated beam structurehaving a first end, a second end and a body extending from the first endto the second end, the body having a first wall member, a second wallmember and a third wall member, each wall member extending from thefirst end to the second end. At the first end, a first flange extendsoutward from the first wall member and integrally formed as a portion ofthe first wall member. Also, at the first end, a second flange extendsoutward from the second wall member integrally formed as a portion ofthe second wall member. The beam is a single unitary component formed ofpultruded composite fiber-reinforced material. Further, the firstflange, second flange and third wall member form a C-shaped coupling atthe first end of the beam and operable for coupling to a rectangularcolumn.

In yet another embodiment, there is provided a cooling tower having asupport frame structure that defines an interior volume. The framestructure includes a plurality of vertical columns, and at least onebeam, made of a material comprising reinforcing fibers, and having afirst end and a second end and connected to a pair of the verticalcolumns. The beam includes a body extending from the first end to thesecond end, with the body having a first wall member, a second wallmember and a third wall member, where each wall member extends from thefirst end to the second end. At the first end, a first flange extendsoutward from the first wall member and is integrally formed as a portionof the first wall member. At the first end, a second flange extendsoutward from the second wall member and is integrally formed as aportion of the second wall member. The first flange, second flange andthird wall member form a C-shaped coupling at the first end of the beamfor coupling to one of the vertical columns. The cooling tower furtherincludes a fluid distribution system to distribute fluid and heattransfer material within the interior volume defined by the supportframe, where the heat transfer material receives fluid from the fluiddistribution system through which the fluid travels, and air movingequipment for causing air to move through the heat transfer material.

In still another embodiment of the present invention, there is provideda method of constructing a support structure. An elongated column isprovided having a rectangular cross-sectional shape, the column having afirst side having an outer surface, a second side having an outersurface, a third side and a fourth side, and at least one apertureextending through the column and through the first side and the secondside of the column; An elongated beam is provided having a first end anda second end, a first side and a second side with each side extendingbetween the first end and the second end, a first flange having a firstaperture and extending outward from the first side of the beam andintegrally formed as a portion of the first side, and a second flangehaving a second aperture and extending outward from the second side ofthe beam and integrally formed as a portion of the second side. Thefirst flanged is positioned adjacent the outer surface of the first sideof the column such that the first aperture aligns with the aperture ofthe column, and the second flange is positioned adjacent the outersurface of the second side of the column such that the second aperturealigns with the aperture of the column. The method further includesextending a fastener through each of the first aperture, the secondaperture and the aperture in the column to couple the beam to thecolumn.

In still another embodiment, there is provided a firewall having aplurality of vertical columns. A first wall panel includes a first outerwall and a second outer wall. The first outer wall is laterally spacedfrom the second outer wall by a first predetermined distance. A secondwall panel is provided that is laterally spaced apart from the firstwall panel by a second predetermined distance. The second wall panelincludes a first outer wall and a second outer wall. The first outerwall is laterally spaced from the second outer wall by a thirdpredetermined distance. Both the first and second wall panels includefiber reinforced pultruded composite material. The first and second wallpanels are coupled to and extend between a first column and a secondcolumn of the plurality of columns and the firewall separates a firstarea of a structure from a second area of the structure, and wherein thefirst and second columns provide load-bearing support for the structure.

In yet another embodiment, there is provided an outer casing supportmember for a tower structure. The support member includes an elongatedcentral member extending a predetermined length and having alongitudinal axis. A first wall member is coupled to the central memberand extends laterally away from the longitudinal axis. This first wallmember includes a first portion and a second portion configured to havean L-shaped cross section. A second wall member is coupled to thecentral member and extends laterally away from the longitudinal axis,and a third wall member is coupled to the central member and extendslaterally away from the longitudinal axis. The first wall member, thesecond wall member, and the third wall member each extend approximatelyat a right angle from an adjacent wall member. An area defined betweenthe first wall member and the second wall member is operable to receivean edge of outer casing material. One of the second and third wallmembers provides an attachment support for attachment to one or morevertical columns in a structure. The casing support member is a singleunitary component formed of composite fiber-reinforced material.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, and theadvantages thereof, reference is now made to the following descriptionstaken in conjunction with the accompanying drawings, wherein likenumbers designate like objects, and in which:

FIGS. 1A is a perspective view of a tower/frame structure in accordancewith the present invention;

FIGS. 1B and 1C illustrate a first bent line (along B-B of FIG. 1A) ofthe structure 100 and a second bent line 160 (along B-B of FIG. 1A withthe first bent line 150 removed);

FIGS. 2A and 2B illustrate a perspective view (FIG. 2A) and a sidecross-sectional view (FIG. 2B) of a column in accordance with presentinvention;

FIG. 2C shows one example of a vertical column and connected first andsecond beams 300;

FIGS. 3A, 3B, 3C, 3D and 3E illustrate a perspective view (FIG. 3A), adetailed perspective view of one end (FIG. 3B), a first and secondembodiment of side cross-sectional views (FIGS. 3C and 3D), and atop/side view of one end (FIG. 3E), all of a beam in accordance with thepresent invention;

FIG. 3F shows a top view of a beam connected to a column (or a side viewof a beam connected to another beam);

FIG. 3G shows another example of a vertical column and connected firstand second beams;

FIGS. 4A, 4B and 4C illustrate a perspective view (FIG. 4A), a detailedperspective view of one end (FIG. 4B), and a cross-sectional view (FIG.4C) of an alternative embodiment of another beam in accordance withpresent invention;

FIG. 4D shows one example of a vertical column and connected first andsecond beams of the alternative embodiment shown in FIGS. 4A, 4B and 4C;

FIGS. 5A and 5B illustrate a perspective view (FIG. 5A) and across-sectional view (FIG. 5B) of a joist beam 500 in accordance withpresent invention;

FIGS. 6A, 6B, and 6C illustrate various views of a cooling tower inaccordance with the present invention, and which incorporates thestructure 100 and various components of the present invention; and

FIGS. 7A and 7B illustrate a perspective view (FIG. 7A) and across-sectional view (FIG. 7B) of a toe board and top trim member inaccordance with present invention;

FIGS. 7C and 7D illustrate a perspective view (FIG. 7C) of a cornercolumn with two attached toe/trim members (illustrating members beingused as top trim) and a cut-away side view (FIG. 7D) of a corner columnwith two attached toe/trim members (illustrating members being used as atoe board), all in accordance with present invention.

FIG. 8 illustrates a cross-sectional view (FIG. 7A) of a double wallpanel member in accordance with present invention; and

FIGS. 9A and 9B illustrate different embodiments of a firewall includingmultiple double wall panels, in accordance with present invention.

DETAILED DESCRIPTION OF THE INVENTION

A prior art cooling tower and frame structure is described in U.S. Pat.No. 5,902,552 to Seawell, et al. (1999), which has been previouslyincorporated herein by reference.

Now referring to FIG. 1A, there is shown a tower/frame structuregenerally designated 100, in accordance with the present invention, thatincludes a plurality of vertical columns 112 and a plurality ofhorizontal beams 114. Diagonal bracing members 116 are included toprovide lateral stability and resistance to wind and earthquakes.Additional diagonal bracing members 116 a and beams 118 are provided foradditional stability, and may be optional, depending on the desired loadcharacteristics and criteria. The term “beam” as used herein, refers tothe beams 114 and also to the bracing members 116, 116 a. As will beappreciated, the structure 100 is shown generally including thestructural support members of a tower structure intended to supportadditional components or materials.

In the embodiment shown, the columns 112 are spaced a predetermineddistance to provide bays. The column spacing distances may be the sameor different, thus different embodiments may have different sized bayshaving footprints that are square or rectangle. In differentembodiments, the spacing between columns 112 can be any distance, andusually ranges between eight and twenty feet, and more particularlybetween twelve and eighteen feet, and in one embodiment is about twelvefeet or greater, and preferably between fourteen to sixteen feet. Thestructure 100 has several tiers or levels, including an air inlet level120 and upper levels 122. Further, the distance between each level maybe different or the same, as desired.

When used in a cooling tower, the upper levels 122 carry fill material,a water distribution system and air intake equipment and/or othercomponents (not shown in FIG. 1A). In a counterflow cooling tower, alarge diameter fan and motor (not shown in FIG. 1A) are mounted on aroof 124 to draw air from air intake level 120 and through the upperlevels 122 to exit. As will be understood, the structure 100 and otherelements and components described herein, are not limited to use in acooling tower, but may be used as, and in, a structural frame to supportany type of equipment or components or for any purpose or buildingstructure. Moreover, FIG. 1A illustrates but one example of thestructure 100 having four bays. Additional bays and configurations maybe included, as desired.

Additional joist members 128 rest on one or more beams 114 and functionto support a floor or the other components at desired levels of thestructure 100.

Now referring to FIGS. 1B and 1C, there is shown a first bent line 150(along B-B of FIG. 1A) of the structure 100 and a second bent line 160(along B-B of FIG. 1A with the first bent line 150 removed). As thestructure 100 is illustrated with four bays, there are three bent lines(two outer and one inner bent lines). As shown, the center column 112 ofthe bent line 160 is shorter than the outer most columns, as the extralength of the outermost columns is utilized as a post for a fenceerected around the roof 124 of the structure 100.

One significant advantage of the present invention is found duringconstruction of the tower frame/structure. Once two bent lines (such asbent lines 150 and 160) are erected and a set of cross beams (ormembers) is in place, using the columns, beams and connections disclosedherein, the structure has substantial load carrying capability at mostor all points along the beams and columns. This provides a high standardof fall protection for workers during construction of the remainingstructure. For example, workers may utilize retractable safety lines foranchoring at one of many possible attachment points. Workers may thenmove about the structure without having to re-anchor the safety linebefore moving to another location. In most designs in accordance withthe invention taught herein, it is likely that this structure will meetor exceed United States OSHA standards (5000 lb. attachment or anchorpoint loads) for fall protection.

Now referring to FIG. 1D (showing a close-up of Detail A of FIG. 1A),there are illustrated several connections or anchor points 180, 182,184, 186, 188 between a column 112 and the beams 114 a, 114 b, 114 c anddiagonal brace members 116. The column 112 includes a plurality ofattachment holes therein, while each of the beams 114 a, 114 b, 114 cand diagonal brace members 116 have one or more attachment holes foralignment with corresponding holes in the column 112. Once aligned, afastener (not shown in FIG. 1D) is inserted into the aligned holes toconnect the respective beam or member to the column 112.

As will be appreciated, the fastener may include any type of mechanicalfastener known to those of ordinary skill in the art, including bolts,screws and pins, and constructed of any suitable material suitable forthe structure 100 application (e.g., non-corrosive such as galvanized orstainless, if used in a cooling tower application). The attachment holesin each of the column 112, beams 114 a, 114 b and 114 c and the members116 are shown as pre-formed or pre-drilled. These may be formed any timeprior to the assembly of the connections 180, 182, 184, 186, 188, andfurther may formed at the time of assembly of the connections. In oneembodiment, a pin is utilized as the fastener, in conjunction with thenovel design aspects of the column 112, beams 114, members 116, 118 andthe connections and connecting mechanism (as shown in FIG. 1D). As such,in this embodiment, a fastener with a tightening function may not benecessary as a connection pin will usually carry the necessary load andprovide moment stability (and as further described below).

Now referring to FIGS. 2A and 2B, there is provided a perspective view(FIG. 2A) and a side cross-sectional view (FIG. 2B) of a column 112 anddesignated using the reference numeral 200, in accordance with presentinvention. The column 200 has four sides 202 a, 202 b, 202 c, 203 d(each side having a surface), with each side having a respectivesidewall 203 a, 203 b, 203 c and 203 d. As shown, the cross-sectionalshape of the column 200 is square. Other rectangular shapes may be used.The sides and sidewalls have outer dimensions X and Y (as shown in FIG.2B), these may also be referred to as cross-sectional dimensions. (Thereferences X and Y do not necessarily reflect the x and y directions inan xyz coordinate system, but are used for reference only.)

As illustrated, the column 200 is substantially hollow (though thecolumn 200 may include inner walls for additional strength, if desired).Each sidewall has a thickness t. In one embodiment, the thickness t issubstantially the same for each sidewall. In other embodiments, thethickness t may be the same for each sidewall in a pair of respectiveopposing sidewalls (and different among the two pairs), or different foreach sidewall.

The dimensions X and Y may be chosen as desired, and may further bedifferent from each other (rectangular) or substantially the same(square). As will be appreciated, it may be beneficial for the column200 to be square (dimension X equals dimension Y) to allow the beams andmembers connected thereto to utilize a standard length flange orextension (of any beam) for the connection. In one specific embodiment,X and Y are approximately 6 inches, and the thickness t is approximately⅜ inch. In another embodiment, both X and Y are about 4 inches orgreater. Other dimensions may be used. Dimensions X and/or Y reflect theoutside dimension (OD) of a given cross-section, as the case may be, ofthe column 200.

The length of the column 200 is generally equal to the desired height ofthe structure 100 (with some columns shorter or longer than others, asper design). In one embodiment, the column 200 is a single, unitarypiece, with lengths ranging from ten to seventy feet. In otherembodiments, depending on the desired height of the structure 100 andother deign considerations, the column 200 may be constructed from twoor more pieces that are connected or spliced together.

Column 200 may be constructed from wood, steel or other metal, orfiber-reinforced plastic (FRP) or other composite materials.

The column 200 includes one or more sets 204, 206 of attachment holes,apertures or openings 208 (hereinafter referred to as “holes”), witheach set including one or more pairs of attachment holes 208. Aparticular set 204, 206 of attachment holes 208 are formed through oneof the sidewalls and its respective opposite sidewall, thus a pair ofcorresponding attachment holes (one located on one sidewall and theother on the opposite sidewall) are operable for receiving a fastenertherethrough both aligned holes. When inserted, the fastener extendsthrough the entire cross-section of the column 200. Each set 204, 206 ofattachment holes 208 corresponds to another set of attachment holes 208(not shown) in one of the beams 114, 116, 118 that are to beconnected/attached to the column 200 (i.e., column 112).

The location (height) of the attachment holes 208 along the column 200depends on the location of the desired connection point with aparticular beam. The number of attachment holes 208 per connection(column-beam connection) may be chosen as desired, and may include one,two, three, four or more holes (as desired and/or depending on the sizeand shape of the particular beam). The attachment holes 208 may beformed by a suitable process or fabrication method, such as by anydrilling or cutting method (or other material removal means) and thelike. As noted above, the holes may be formed during the actual erectionof the structure 100, but may be advantageously pre-formed at some pointprior to construction (such as during the column fabrication process orshortly thereafter).

Each set 204, 206 of attachment holes 208 (in sidewalls 203 a and 203 c)for a particular column-beam connection is positioned closer (or nearer)to one of the sidewalls 203 b than the other sidewall 203 d, as shown.This advantageously allows for another beam placement and column-beamconnection (via attachment holes through sidewalls 203 a and 203 c butnearer the sidewall 202 d, not shown) to be made on the opposite side(180 degrees) of the column 200 (e.g., see FIG. 1D and connection points182 and 184 for beams 114 b). In one specific embodiment, the sets ofattachment holes 204, 206 are laterally spaced from the sidewall 202 bapproximately one inch and laterally spaced more than one inch from thesidewall 202 d), and the diameter/dimension of the holes is about ½inch. Other lateral spacings and attachment hole diameters/dimensionsmay be utilized, including centering the set of attachment holes (in theevent that no additional column/beam connection will be made at thatvertical height). As will be appreciated, the attachment holes 208 asshown are circular, but may other shapes, e.g., slotted, square,rectangle, oval, etc., if desired.

Additionally, the positioning of the particular attachment holes 208 toa sidewall (closer to one of the sidewalls than the mid-point of thecolumn 200 where a beam will extend outward from that particularsidewall) helps reduce or eliminate “creep.” In prior art systems, thefasteners are tightened to increase moment resistance of the connection.Since connection points always generally become loose due to wear, thereis a desire to tighten the fasteners as tight as possible to ensuremoment resistance. However, when fasteners are placed in the midpoint ofa hollow FRP column, there is an opportunity to overtighten the fastenerand the FRP structure. As such, crush-resistant sleeves are typicallyutilized. It has been determined by the inventors, that when theposition of the fastener is closer to the sidewall than the midpoint,tightness of the connection is not as critical because, a connection inaccordance with the present invention, provides sufficient momentresistance without the need for substantial tightening of the fastenerabout the connection point that might result in crushing the column 200.Thus, tightening needs are significantly reduced, thus eliminating anysleeves or plates. It has been determined that pins may be utilized asthe fasteners, however, for safety and cost reasons, standard bolts orscrews may be more advantageous.

Now referring to FIG. 2C, there is shown one example of the verticalcolumn 200 having a first horizontal beam 240 and a second horizontalbeam 250 connected. The first beam 240 is connected at a first locationalong the column 200 and the second beam 250 is connected at a secondlocation along the column 200. Each connection includes a set ofattachment holes 242, 252 and plurality of fasteners 260 extendingthrough the respective attachment holes 242, 252 and thus through therespective beam 240, 250 and the column 200. As shown, an additional setof attachment holes is provided to allow another column-beam connectionof another beam (not shown) extending from the column 200 along the sameplane as the beam 240. Other configurations are possible, and that shownin FIG. 2C is one example.

Now referring to FIGS. 3A, 3B, 3C, 3D and 3E there are shown aperspective view, a detailed perspective view of one end (FIG. 3B), afirst and second embodiment of side cross-sectional views (FIGS. 3C and3D), and a top/side view of one end (FIG. 3E) of a beam 114 and which isdesignated using the reference numeral 300, in accordance with presentinvention. The elongated beam 300 includes a first end 301 a and asecond end 301 b, and further includes four sides 302 a, 302 b, 302 c,302 d (each side having a surface), with each side having a respectivesidewall 303 a, 303 b, 303 c and 303 d. As shown, the cross-sectionalshapes of the two embodiments (FIGS. 3C and 3D) are rectangular, and maybe square. Other rectangular shapes may be used. The sides and sidewallshave outer dimensions X and Y (as shown in FIGS. 3B, 3C and 3D).

Now turning specifically to FIG. 3B, one of the ends 301 a, 301 b of thebeam 300 is shown. At the end, one side and sidewall 302 b, 303 bincludes a first connection extension, tab or flange 310, and theopposing side and sidewall 302 d, 303 b includes a second connectionextension, tab or flange 312. The extensions 310, 312 extend furtheroutward than the adjacent sides and sidewalls (302 a, 303 a and 302 c,303 c) thus forming a C-shaped end for the beam 300. The distancebetween the inner walls of the flange 310 and the flange 312 is referredto as an inner dimension (ID) while the distance between the outer wallsis the outer dimension (OD). In one specific embodiment, the beam 300 isformed with a flush end (i.e., all sidewalls extend the same length),and material from the areas 320 and 322 is cut out or removed to formthe C-shaped end, thus forming the extensions or flanges 310, 312.

The connection extensions or flanges 310, 312 provide, in essence, anintegrally formed connection or mounting plate, are integrally formedwith the rest of the beam 300, and operable to be positioned adjacent tothe sidewalls of the column 200 and mounted to the outside of the column200. Each of the connection extensions or flanges 310, 312 provide anarea that is positioned adjacent a sidewall area of the column 200.

The extensions or flanges 310 and 312 are integrally formed, as well asunitary, with the sidewalls 303 b and 303 d, respectively.

The connection extensions 310 and 312 each include one or moreattachment holes, apertures or openings 308 (hereinafter referred to as“holes”). The attachment holes 308 are formed through one connectionextension 310 and corresponding attachment holes 308 are formed throughthe other connection extensions 312, and are operable for receiving afastener therethrough both aligned holes. When inserted, the fastenerextends through the entire cross-section of the beam 300. As will beappreciated, the attachment holes 308 correspond to another set ofattachment holes 208 in the column 200 or in another beam (not shown).

As illustrated in FIGS. 3B, 3C and 3D, the beam 300 is substantiallyhollow (though the beam 300 may include inner walls for additionalstrength, if desired). As shown in FIGS. 3C and 3D, each sidewall has athickness t1 or t2. In one embodiment, the thickness t is substantiallythe same for all sidewalls (t1 equals t2). In other embodiments, the twoopposing sidewalls may have the same thickness (t1 or t2), or eachsidewall may have a different thickness dimension.

The dimensions X and Y may be chosen as desired, and may further bedifferent from each other (providing a rectangular shape) orsubstantially the same (square). In one specific embodiment shown inFIG. 3C, the approximate dimensions are: X (or OD)=6.56 inches, Y=6.0inches, t1=0.25 inch, and t2=0.375 inch, resulting in the innerdimension (ID) between the flanges of approximately ID=6.062 inch (suchbeam is referred to by the inventors as a “tie beam”). In anotherspecific embodiment shown in FIG. 3D, the approximate dimensions are:X=6.75 inches, Y=10.0 inches, t1=0.3 inch, and t2=0.5 inch, resulting inthe inner dimension (ID) between the flanges of approximately ID32 6.125inch (such beam is referred to by the inventors as a “light beam”). Inyet another specific embodiment (not shown) the approximate dimensionsare: X=6.75 inches, Y=11.0 inches, t1=0.3 inch, and t2=0.5 inch,resulting in the inner dimension (ID) between the flanges ofapproximately ID=6.125 inch (such beam is referred to by the inventorsas a “medium beam”). As will be appreciated, other X and Y dimensionsand thickness t1 and t2 may be used, as desired. In another embodiment,both X and Y are at least four inches or greater. Dimensions X and/or Yreflect the outside dimension (OD) of a given cross-section, as the casemay be, of the beam 300.

It will be understood that it is advantageous, and one aspect of thepresent invention is, to have the inner dimension (ID) (cross-section)between the flanges 310, 312 of the beam 300 to be substantially equalto (or slightly larger, given construction requirements and tolerances)the outer dimension (X or Y) of the column 200. Due to the thicknessaspect of the beam 300, this results in the outer dimension (X)(measured between the outside walls of the sidewalls incorporating theflanges) of the beam 300 to be slightly larger than the column (or beam)to which it will attach/couple. As such, the columns and beams of thepresent invention are specifically designed to provide the necessarycolumn-beam (or beam-beam) connection without any additional sleeves,plates, or spacers.

For example, when the outer dimension (OD) (the X or Y dimension) of thecolumn 200 is equal to X inches, the inner dimension (ID) of the beam300 should also be approximately X inches. Advantageously, it should beX plus a tolerance distance (small) to allow the C-shaped section of thebeam 300 to be set in place around the column 200. Such tolerancedistance may be in the range from zero to 0.5 inches, and moreparticularly is less than about 0.25 inch, and may be even smaller.Accordingly, the ID of the beam 300 is approximately equal to, orslightly larger than, the OD of the column 200 measured at the locationswhere the beam 300 and the column 200 attach to each other. This mayalso apply to the connection of two beams (where the ID of one beam isapproximately the same, or slightly larger than, the OD of the otherbeam if two beams are attached).

Now referring to FIGS. 3E and 3F, there is shown a top/side view of oneend 301 a, 301 b of the beam 300 prior to connection to the column 200and a top/side view after connection. As will be appreciated, given thedesign criteria, one end or both ends of the beam 300 may include theconnection extensions or flanges, as described herein. Attachment holes308 in the flanges 310, 312 are shown with dotted lines. Each of theflanges 310, 312 extend a length L from an outer edge 324 or 326 of anadjacent sidewall 303 a or 303 c. The lengths L for each flange may bedifferent, but are usually the same.

The length L is of a length to provide an overlap of the flanges 310,312 with the outer sides and sidewalls 202, 203 of the column 200 toenable adequate connection of the beam to the column. A small gap,identified by reference numeral 332, will usually exist between edges324, 326 of the beam sidewalls 303 a, 303 c. The size of the gap 332 andthe amount of overlap desired will determine the suitable length L. Itwill be understood that the location of the attachment holes will alsoplay a factor in determining the overall positioning. In one embodiment,regardless of the size of the gap 332, the length L may be approximatelyequal to or greater than one-half the outer dimension (X or Y, as shown)of the column 200 (or beam).

In another specific embodiment, if the beam and column are positionedsuch that the gap 332 is relatively small, the length L may beapproximately equal to one-half the outer dimension (X or Y, as the casemay be) of the column/beam to which it will attach/couple, and may beless than one-half the outer dimension. In such case, making the lengthL of the flanges 310, 312 equal to, or slightly less than the outerdimension of the column 200 allows for an additional beam to beattached/coupled to the column 200 at the same vertical location (orhorizontal location, if attached to another beam), thus allowing twobeams to be attached to the column 200 at the same height (i.e. in thesame horizontal plane or point). An example of this is shown in FIG. 3G.The length L may be longer, if desired. In another embodiment, thelength L is substantially equal to or less than one-half the OD of thecolumn 200. In a specific example, if the OD of the column 200 equal 6inches, the length L is approximately three inches, and may beapproximately three and one-eighth inches. This will assist inconstruction tolerances as there will then be a sufficient gap forclearance.

To assist in providing multiple connection points at the same locationon a column 200 (or beam), the attachment holes 208, 308 and the lengthL of the flanges 310, 312 are configured so that the outer edges of theflanges 310, 312 extend to a point that is about equal to, or less than,about one-half the outer dimension of the column 200 (as shown in FIG.3F), e.g., extending up to the midpoint. If only one connection iscontemplated, then the flanges may extend farther than the mid-point, ifdesired.

The cross-section dimensions (the X outside diameter and the innerdimension) of the sidewall(s) (that include the flanges 310, 312) alongthe entire length of the beam 300 are substantially equal to the ID andOD between the two flanges 310 and 312. Moreover, the thickness of thesidewall 303 b measured along the length of beam 300 is substantiallyequal to the thickness of the flange 310, and similarly, the thicknessof the sidewall 303 d measured along the length of beam 300 issubstantially equal to the thickness of the flange 312. Further, theflanges 310 and 312 are integrally formed as part of, and unitary with,the respective sides and sidewalls 302 b, 303 b and 302 d, 303 d.

Now referring specifically to FIG. 3F, there is shown a top view of thebeam 300 connected to the column 200 (or a side view of a beam connectedto another beam). A mechanical fastener 330 extends through theplurality of attachments holes 308 (in the flanges of the beam 300) andattachment holes 208 (in the column 200). Typically, more than onefastener 330 is used.

The overall length of the beam 300 is generally equal to the desiredbeam span of the structure 100 (with some beams shorter or longer thanothers, as per the design). In one embodiment, the beam 300 is a single,unitary piece, with lengths ranging from ten to twenty feet. In otherembodiments, beam length is between twelve and sixteen feet, greaterthan twelve feet, and/or up to sixteen feet, and perhaps up to eventwenty feet.

Now referring to FIG. 3G, there is shown one example of the verticalcolumn 200 having a first horizontal beam 370 and a second horizontalbeam 380 connected. Beams 370, 380 are similar to the beam 300. Thefirst beam 370 is connected at a first location along the column 200 andthe second beam 370 is connected at a second location, though at thesame vertical height (i.e., both the beams are in the same plane andextend in the same longitudinal direction), along the column 200. Eachconnection includes a set of attachment holes 372, 382 and plurality offasteners 330 extending through the respective attachment holes 372, 382and thus through the respective beam 370, 380 and the column 200. Otherconfigurations are possible, and that shown in FIG. 3G is one example.

When the column 200 and the beam 300 described herein are utilized andconnected in the manner provided and designed and constructedappropriately, the connection provides an anchor point that meets orexceeds the United States Occupational Safety and Health Administration(OSHA) anchor requirement of 5000 lbs. As such, utilizing a pultrudedFRP 6×6 (inches) column and a pultruded FRP beam having dimension of atleast 6×6 (inches) and a beam length of twelve feet or greater (andpreferably up to sixteen feet), the present invention provides columnspacing distance d of twelve to sixteen feet (and perhaps higher), withthe beams spanning this distance d, and the connections of thecolumn-beam provide anchor points that meet or exceed 5000 lbs.

Now referring to FIGS. 4A, 4B and 4C there are shown a perspective view(FIG. 4A), a detailed perspective view of one end (FIG. 4B), and across-sectional view (FIG. 4C) of an alternative embodiment of the beam300, and which is designated using the reference numeral 400, inaccordance with present invention. The elongated beam 400 includes afirst end 401 a and a second end 401 b and has generally a rectangularcross-sectional shape, and more particularly an “I” cross-sectionalshape. The beam 400 includes a first sidewall 402, a second sidewall 404and an inner wall 406. The inner wall 406 extends between and connectsto the first sidewall 402 and the second sidewall 404. The overall outerdimensions are shown as dimensions X and Y (as shown in FIGS. 4B and4C).

Now turning specifically to FIG. 4B, one of the ends 401 b of the beam400 is shown. At the end, the first sidewall 402 includes a firstconnection extension, tab or flange 412, and the second sidewall 404includes a second connection extension, tab or flange 410. Theextensions 410, 412 (similar to the extensions/flanges of the beam 300)extend further outward than the adjacent side of the inner wall 406 thusforming a C-shaped end for the beam 400. The distance between the innerwall of the flange 410 and the flange 412 is (similar to that describedwith respect to the beam 300) the inner dimension (ID) while thedistance between the outer walls is the outer dimension (OD). In onespecific embodiment, the beam 400 is formed with a flush end (i.e., thewalls 402, 404, 406 extend the same length), and material from the areas420 (part of the inner wall 406) is cut out or removed to form theC-shaped end, thus resulting in the formation of the extensions orflanges 410, 412.

Similar to the extensions or flanges 310, 312, the connection extensionsor flanges 410, 412 provide, in essence, an integrally formed connectionor mounting plate (integrally formed, as well as unitary, with the restof the beam 400) and operable to be positioned adjacent to the sidewallsof the column 200 and mounted to the outsides of the column 200. Each ofthe connection extensions or flanges 410, 412 similarly provide an areathat is positioned adjacent a sidewall area of the column 200.

The connection extensions 410 and 412 each include one or moreattachment holes or apertures 408 and are similar to the attachmentholes 308.

As illustrated in FIGS. 4B and 4C, the cross-section of the beam 400 isI-shaped (the beam 400 may include additional inner walls for additionalstrength, if desired). The sidewall 402 has a thickness t1, the sidewall404 has a thickness t2 and the inner wall has a thickness t3. In oneembodiment, the thickness t is substantially the same for all sidewalls(t1 equals t2 equals t3). In other embodiments, the respective thicknessmay vary.

The dimensions X and Y may be chosen as desired. In one specificembodiment shown in FIG. 4C, the approximate dimensions are: X=6 inches,Y=6.62 inches, t1=t2=t3=0.25 inch, resulting in the inner dimension (ID)between the flanges of approximately ID=6.12 inch (such beam is referredto by the inventors as a “casing beam”). As will be appreciated, other Xand Y dimensions and thickness t1, t2 and t3 may be used, as desired. Inanother embodiment, both X and Y are at least four inches or greater.Dimensions X and/or Y reflect the outside dimension (OD) of a givencross-section, as the case may be, of the beam 400.

As described above with respect to beams 300, one aspect of the presentinvention is to have the inner dimension (ID) (cross-section) betweenthe flanges 410 and 412 of the beam 400 to be substantially equal to (orslightly larger, given construction requirements and tolerances) theouter dimension (X or Y) of the column 200.

Now referring to FIGS. 3E and 3F, though these figures are described andinclude reference numerals relating to the beam 300, these figures mayalso be referenced to show a top/side view of one end 401 b of the beam400 prior to connection to the column 200 and a top/side view afterconnection. As such, FIGS. 3E and 3F (and description herein) aresimilarly applicable to describe the functioning and attributes of thebeam 400. The beam 400 is a specific embodiment (I-shaped versusrectangular shaped) of the beam 400. As such, reference is made to thedescription above, and the corresponding/similar parts of the beam 400have the same or similar description, attributes, and functionality, asthose parts of the beam 300 shown in the FIGURES.

Now referring to FIG. 4D, there is shown one example of the verticalcolumn 200 having a first horizontal beam 470 and a second horizontalbeam 480 connected. Beams 470, 480 are similar to the beam 400. Thefirst beam 470 is connected at a first location along the column 200 andthe second beam 470 is connected at a second location, though at thesame vertical height (i.e., both the beams are in the same plane andextend in the same longitudinal direction), along the column 200. Eachconnection includes a set of attachment holes 472, 482 and plurality offasteners 330 extending through the respective attachment holes 472, 482and thus through the respective beam 470, 480 and the column 200. Otherconfigurations are possible, and that shown in FIG. 4D is one example.

It should be noted that though the FIGURES and description generallydescribe columns and beams, and illustrate column-beam connections, thepresent invention contemplates connection of beams (beams 300, 400) toother beams.

Though not shown, the ends of the beams 300, 400 may be cut diagonal toallow for diagonal attachment to a column (or other beam). As such, thebeams may also function as diagonal bracing members for bracing betweencolumns. In particular, a beam such as the beam 400 may be particularlyuseful for such application.

When constructed using fiber reinforced plastic (FRP), each of thecolumns 200 and beams 300, 400 are unitary and integrally formed.Further, the beams 300, 400 may be utilized as beams to carry joists, oras joists themselves. Further the beams may be utilized to carry loadsand may be used for other or additional purposes, such as for attachmentmeans for outer casing materials, etc.

In a specific embodiment, the column 200 and the beam 300, 400 are madeof a material containing glass fiber, or other composite or reinforcingmaterial(s). The column 200 is made of pultruded fiber reinforcedplastic (FRP) and may include some fire resistant and/or non-fireresistant materials, as will be understood by those in the art. In oneembodiment, the columns and beams (and other plastic structuresdescribed herein) are constructed using brominated resin for fireretardant characteristics. Pultruded FRP structures or members aregenerally those produced by pulling glass fibers or mats (or othercomposite or reinforcing material) through a die with a resin material.Any reinforcing fiber or other materials may be used, and any type ofresin material, such as polyurethane, vinylester, polyester, or otherpolymer materials may be used, as known to those in the art. In oneembodiment, the plastic structures include carbon to increase strength,and in another embodiment, the reinforcing fiber may be defined ascarbon material or other strength increasing materials.

The columns 200 and beams 300, 400 are manufactured using a typicalpultrusion process (resin bath, die injection, etc.) using diescorresponding to the desired cross-sectional shape of the column orbeam. As the pultruded component (column, beam, etc.) is pulled throughthe die and solidifies, the component is cut to length per the desiredlengths, as specified herein (the components may also be cut to astandard length, and then re-cut to the needed length at a later time).Each column 200 and beam 300, 400 is integrally formed, and of unitaryconstruction. After the columns or beams are made to the appropriatelength, attachment holes are formed (as previously described herein) atthe suitable locations and the end(s) of the beams are formed to createthe connection extensions or flanges (as described). The system of thepresent invention allows for the custom design of a tower/structure 10with components that are specially constructed that allows for quick andefficient erection of the structure at the desired site. Though apultrusion process is disclosed, it may be possible to utilize anothermanufacturing process to create the composite plastic structures.

Now referring to FIGS. 5A and 5B, there are shown a perspective view(FIG. 5A) and a cross-sectional view (FIG. 5B) of a joist beam 500 inaccordance with present invention. The elongated joist beam 400 includesa first end 501 a and a second end 501 b and has generally a double “I”cross-sectional shape. The joist 500 includes a first sidewall 502, asecond sidewall 504, a first inner wall 506 and a second inner wall 508.Each of the inner walls 506, 508 extends between and connects to thefirst sidewall 502 and the second sidewall 504. The overall outerdimensions are shown as dimensions X and Y (as shown in FIG. 5B).

As illustrated in FIG. 5B, the cross-section of the joist 500 is doubleI-shaped (the joist 500 may include additional inner walls foradditional strength, if desired). The sidewall 502, the sidewall 504,the first inner wall 506 and the second inner wall 508 each have atthickness, t1, t2, t3, t4, respectively (not shown). In one embodiment,the thickness t is substantially the same for all members. In otherembodiments, the respective thickness may vary.

The dimensions X and Y may be chosen as desired. In one specificembodiment shown in FIG. 5B, the approximate dimensions are: X=4 inches,Y=6 inches, t1=t2=0.25 inch, and t3=t4=0.15 inch (such joist is referredto by the inventors as a “heavy joist”, while “lighter” joists may alsobe utilized, all depending on the load). As will be appreciated, other Xand Y dimensions and thickness t1, t2 and t3 may be used, as desired. Inanother embodiment, both X and Y are at least three inches or greater.Dimensions X and/or Y reflect the outside dimension (OD) of a givencross-section, as the case may be, of the joist 500.

The joist 500 is similarly constructed and made using a pultrusionprocess as the beams and columns. The joist 500 is integrally formed,and of unitary construction. The joists may additionally be constructedwith polyurethane and stronger reinforcement materials, to increase thestrength and load carrying capabilities of the joist 500. Joists of thetype typically span more than one bay.

As such, the overall length of the beam 500 is generally equal to thedesired joist span, or partial span, of the structure 100 (with somejoists shorter or longer than others, as per the design). In oneembodiment, the beam 500 is a single, unitary piece, with lengthsranging from ten to fifty feet. In other embodiments, joist length isbetween fourteen and forty feet, greater than twenty feet, and/orgreater than twenty-five feet.

Now referring to FIGS. 6A, 6B, and 6C, there is illustrated variousviews of a cooling tower 600 in accordance with the present invention,and that incorporates the structure 100 and various components describedherein. It will be understood that the cooling tower 600 and thestructures shown throughout the remainder of the figures and describedherein represent examples of the present invention, and the invention isnot limited to the structures shown and described.

The cooling tower, generally designated by reference numeral 600 isshown with two cells 632. Each cell 632 is shown as a square aboutforty-two feet on each side, so its overall footprint is about forty-twoby eighty-four feet. Each cell 632 is shown with nine (3×3) bays, witheach bay about fourteen by fourteen feet. Other configurations arecontemplated, including a single cell or multiple cells, with each cellhaving any number of bays (e.g., 2×2, 3×3, or uneven combinations). Eachcell 632 includes a fan 634 held within a fan shroud 636 that maygenerally be formed of a fiber reinforced plastic structure that isassembled on top of the cooling tower 600. The fan 634 sits atop ageared fan-speed reducer which itself receives a drive shaft extendingfrom a fan motor. The fan, fan speed reducer and motor may be mounted asconventional in the art, as for example, mounting on a beam such as asteel tube or pipe of appropriately chosen structural characteristicssuch as bending and shear strength and torsion resistance, or theequipment may be mounted on a beam or joist constructed of FRP. Themotor and beam may be located on the roof or top of the cooling tower600 or within it. In the illustrated embodiment, the fan shroud 636 ismounted on top of a flat deck 638 on top of the cooling tower 600 with aguard rail 640 around the perimeter. A ladder 641 or stairway 643 mayalso be provided for access to the deck, and walkways may also beprovided on the deck.

Beneath the deck 638 are the upper levels 642 (122 in FIG. 1A) of thecooling tower 600 and beneath the upper levels 642 is the bottom or airintake level 644 (120 in FIG. 1A). Beneath the air intake level 644 is ameans or mechanism for collecting cooled water from the fill system. Inthe illustrated embodiment, the collecting means or mechanism is a basin646, into which cooled water drips and is collected.

The exterior of the upper levels 642 may be covered with a casing orcladding 648 designed to allow air to pass through into the coolingtower during, for example, windy conditions, and may be designed to besacrificial, that is, to blow off when design loads are exceeded. Thecasing 648 may be made of fiber reinforced plastic or some othermaterial and may comprise louvers.

As shown in FIG. 6C, the upper levels 642 include a fill level 650 andwater distribution level 652. The fill level 650 is below the waterdistribution level 652, so that water is distributed to drip through thefill level 650 to the collecting basin 646 below. Air is moved throughthe fill level 650 past the water to cool it. The illustrated fan 634comprises one possible means for causing air to move through the fillsystem, although other means or mechanisms may b used, such as a blowern a cross-flow arrangement.

As known in the art, the fill level 650 is filled with fill material 654that provides a heat transfer function and media. Generally, the fill isopen-celled material that allows water to pass downwardly and air topass upwardly, with heat transfer taking place between the water and airas they pass. Open-celled clay tile or polyvinyl chloride materials orother open cell heat transfer media may be used. Various types of fillmaterial may be used, and such fill material is commercially available.The cooling tower 600 of the present invention is not limited to use ofany particular type of fill material. The present invention is alsoapplicable to cross-flow designs.

A water distribution system 649 in the water distribution level 652above the fill level 650 includes a distribution header 656 thatreceives hot water from a supply pipe (not shown) that may be connectedto the inlet 658 on the exterior of the cooling tower. One distributionheader 656 extends across the width of each cell, and each is connectedto a plurality of lateral distribution pipes 660 extendingperpendicularly from the header 656 to the opposite edges of each cell.The lateral distribution pipes 660 are spaced evenly across each bay,with lateral distribution pipes being provided in each of the fourteenby fourteen foot bays of the illustrated embodiment. Larger or smallerbays may be provided with an appropriate number and spacing of waterdistribution pipes provided.

Each lateral distribution pipe 660 has a plurality of downwardlydirected spray nozzles 663 connected to receive hot water and spray itdownward in drops onto the fill material 654, where heat exchange occursas gravity draws the water drops down to the basin and the fan drawscool air up through the cooling tower. Each lateral distribution pipemay have, for example, ten nozzles, so there may exist eighty nozzles ineach bay 662. The water distribution system 649 is shown and describedfor purposes of illustration only and other designs may also beutilized.

The cooling tower of the present invention also has a tower/framestructure 100 (also refer to FIG. 1A) to support the fan system, waterdistribution system and fill material. The structure 100 defines aninterior volume 665 within which the fill material and substantialportion of the water distribution system are contained. The frame orstructure 100 includes a plurality of vertical columns 112 andhorizontal beams 114, as described previously. The horizontal beams 114are attached to the columns 112 in a novel manner, as described hereinto provide a rigid frame/structure with bays larger than the prior artand/or with fewer connections and/or components, thus simplifyingconstruction and lowering the cost of building the field erectedframe/structure 100, and ultimately the cooling tower 600 tower.

The cooling tower 600 further includes the collecting basin 646 thatdefines a base 691 on which the vertical columns 112 are mounted throughfootings 686. The types of footings and connections available aregenerally known to those in the art.

The cooling tower 600 generally includes the structure 100 (andcomponents) generally shown in FIG. 1A.

As such, the frame/structure 100 includes a plurality of interconnectedcolumns, beams and joists that provides a supporting structure for theother components of the cooling tower 600. Additional components and/ormore detailed descriptions of these components in the cooling tower 600are described in U.S. Pat. No. 5,902,522, which is incorporated hereinby reference.

Now referring to FIGS. 7A, 7B, 7C and 7D, there are shown a perspectiveview (FIG. 7A) and a cross-sectional view (FIG. 7B) of a toe board andtop trim member 700 (referred hereinafter as “toe/trim member”) inaccordance with present invention. The elongated toe/trim member 700includes a first end 701 a and a second end 701 b and has generally a“+” cross-sectional shape (or four-prong star shape). The toe/trimmember 700 includes a first wall 702, a second wall 704, a firstL-shaped wall 706, and a second L-shaped wall 708. The first L-shapedwall 706 includes a first portion 706 a and a second portion 706 b.Similarly, the second L-shaped wall 708 includes a first portion 708 aand a second portion 708 b. Each wall 702, 704, 706, 708 extendsradially from an axis point (or member) or connection point (or member)710 extending longitudinal along a length of the toe/trim member 700.This length may be a portion, the entire length or substantially theentire length. The walls 702, 704, 706, 708 may also be described aslaterally extending transversely from the member 710. The member 710 maybe referred to as a central or main member. In the embodiment shown, allwalls connect to each other at the point/area (or member) 710 (a singlepoint/area/member of connection for all the walls is not necessary,though desirable).

As illustrated, the first wall 702 extends opposite the second L-shapedwall 708, while the second wall 704 extends opposite the first L-shapedwall 706. Each of the walls extends at approximately right angles froman adjacent wall, including the second portions 706 b, 708 b extendingfrom the respective first portions 706 a, 708 b. The overall outerdimensions are shown as dimensions X and Y (as shown in FIG. 7B). Thedimension C illustrates the distance between the wall 702 and an outermember 706 a of the first L-shaped wall 706. As will be appreciated, thearea defined between the first wall 702 and the L-shaped wall 706 willcarry or receive an edge of casing or cladding material or panels (shownin FIG. 7D). The dimension C is approximately equal to the thickness ofthe cladding or casing panels. Each of the walls 702, 704, 706 and 708has a thickness, t1, t2, t3, t4, respectively (not shown). In oneembodiment, the thickness t is substantially the same for all members.In other embodiments, each respective thickness may vary.

The dimensions X and Y may be chosen as desired. In one specificembodiment shown in FIG. 7B, the approximate dimensions are: X=3.6inches, Y=6 inches, t1=t2=t3=t4=0.2 inch. As will be appreciated, otherX, Y and C dimensions and thickness t may be used, as desired. Inanother embodiment, both X and Y are at least three inches or greater.

The toe/trim member 700 is similarly constructed (as the columns, beamsand joists) and may be made using a pultrusion process. The member 700is integrally formed, and of unitary construction. The length of thetoe-trim member 700 can be any desired length, and is chosen to spanbetween two or more outer columns 112 of the structure 100, or asneeded. In one embodiment, the toe/trim member 700 is a single, unitarypiece, with lengths ranging from ten to sixty feet, and in oneembodiment, is equal to or greater than the column spacing.

Now referring to FIGS. 7C and 7D, there are shown a perspective view(FIG. 7C) of a corner column 112 with two attached toe/trim members 700c, 700 d (illustrating the top/trim members being used as top trim) anda cut-away side view (FIG. 7D) of a corner column 112 with two attachedtoe/trim members 700 a, 700 b (illustrating the top/trim members beingused as a toe board) in accordance with present invention.

As illustrated, the wall 702 and a portion of the second L-shaped wall708 form attachment or mounting plates for mounting to an outer wall ofthe column 112 (one or both may be used for attaching). The wall 702and/or second portion 706 b (of wall 706) may also provide attachmentlocations for the casing panels 648. Any fastening or attachment means(not shown) and methods may be utilized, such as bolts, screws, bonding,etc., and the like. When used as a trim member (FIG. 7C) the wall 702and wall 706 of the respective member 700 c, 700 d function to receiveand stabilize the casing or cladding panels 648 c, 648 d. When used as atoe board (FIG. 7D) the wall 702 and wall 706 of the respective member700 a, 700 b function to receive, stabilize and support the casing orcladding panels 648 a, 648 b.

The corrugated nature of standard casing panels 648 allows air leakageat the bottoms and tops of the panels, which is undesirable. As such,the toe/trim member 700 of the present invention provides a single andunitary building component that provides several functions: reduces oreliminates the undesirable air flow, supports and stabilizes the casingpanels, and provides a source of attachment for the casing panels.

It will be understood that a portion of the wall 704 will be removed(cut-away) at the locations where the toe/board member abuts the column112 (or other beam or column or structure, as needed) formounting/attachment. As will be appreciated, the wall 704 of thetoe-trim member 700 may be optional, however, it increases the strengthof the overall toe/board member 700.

Now referring to FIG. 8, there is illustrated a cross-section of adouble wall panel member 800. The panel 800 includes a first wall 802and a second wall 804, with the walls 802, 804 spaced laterally fromeach other. Each wall 802, 804 has an outer surface and an innersurface. One or more inner walls 806 interconnect the first wall 802 andthe second wall 804, as shown, to couple the walls 802, 804 together.The ends may be configured to interconnect to provide a mechanism tocouple two panels 800 together, as shown in FIG. 8.

The dimension X and Y may be chosen as desired, however, in theembodiment shown, X is between two and five feet, and Y is equal to orgreater than about 1 inch. In another embodiment, Y is between about ¾and 2 inches. Each of the walls 802, 804, 806 has a thickness, t1, t2,and t3, respectively (not shown). In one embodiment, the thickness t issubstantially the same for all members. In other embodiments, eachrespective thickness may vary.

The double wall panel 800 (or member) is similarly constructed (as thecolumns, beams, joist) and may be made using a pultrusion process. Inanother embodiment, the panel 800 includes a fire retardant material,such as brominated resin. The panel 800 is integrally formed, and ofunitary construction. The length of the panel 800 can be any desiredlength, and is chosen to span between two or more columns 112 of thestructure 100, or as needed. In one embodiment, the double wall panel800 is a single, unitary piece, with lengths ranging from ten to sixtyfeet, and in one embodiment, is equal to or greater than the columnspacing.

Multiple double panel walls 800 are utilized to form a firewall (asdescribed below) between individual adjacent cells 632. In the event ofa fire in one cell, the firewall advantageously prevents (or reduces thepotential of) the fire from spreading to an adjacent cell. In someapplications, it is desirable that each cooling cell (within a coolingtower structure having multiple cells) operate independently of eachother. Thus, to reduce the risk that a fire in one cell will spread toanother cell, prior art cooling towers incorporated an expensive firesprinkler system into the structure. However, when a firewall structureis utilized that meets certain insurance industry (or other industry)guidelines or tests, the need for such a sprinkler system may beeliminated. Accordingly, the present invention provides a firewallstructure, when constructed between cells, that increases fireresistance between cells and may reduce or eliminate the need for a firesprinkler system.

Now referring to FIG. 9A, there is shown a first embodiment of afirewall 900 a in accordance with the present invention. A cooling tower(such as tower 600 in FIGS. 6A-6C) includes one or more columns 902(similar to columns 112 in FIG. 1A) delineating between two adjacentcooling cells 632 (Cell 1 and Cell 2). Beams 904 and 906 are shown forillustration purposes only.

A first wall 910 is positioned adjacent to a first side of the column902, while a second wall 912 is positioned adjacent to a second side ofthe column 902. The first wall 910 and the second wall 912 are spacedapart by a distance A, as shown in FIG. 9A. Each of the first and secondwalls 910, 912 extends vertically and horizontally substantially theentire area between the two cells 632 (i.e., the cross-sectional areabetween the two cells). The first wall 910 includes one or more doublepanel walls 800 (described previously) to form the wall 910. Similarly,the second wall 912 includes one or more double panel walls 800(described previously) to form the wall 912. The double panel walls 800are attached to the column 902. Optionally, one or more spacers 914, 916may be used, that space the walls 910, 912 from the column 902 (e.g., ½to 1 inch, or greater). The spacers 914, 916 may also be constructed ofplastic material, such as fiber-reinforced composite material with fireretardant material.

In the embodiment shown in FIG. 9A, the column 902 is positioned betweenthe first wall 910 and the second wall 912 and by design provides aspace (spacing) between the double wall panels of the first and secondwalls 910, 912, respectively. In one embodiment, the dimension A(spacing between the first and second walls 910, 912) is at least equalto the width of the column 902. In other embodiments, the spacing may beabout one inch or greater, may be three inches or greater, or may be sixinches or greater.

Now referring to FIG. 9B, there is shown a second embodiment of afirewall 900 b in accordance with the present invention. Beams 904 and906 are shown for illustration purposes only.

A first wall 910 a is positioned adjacent to a first side of the column902, while a second wall 912 a is positioned adjacent the first wall 910a. The first wall 910 a and the second wall 912 a are spaced apart by adistance A, as shown in FIG. 9B. Each of the first and second walls 910,912 extends vertically and horizontally in an amount substantially equalto the cross sectional area between the two cells 632. The first wall910 a includes one or more double panel walls 800 (described previously)to form the wall 910 a. Similarly, the second wall 912 a includes one ormore double panel walls 800 (described previously) to form the wall 912a. The double panel walls 800 are attached to the column 902 (directlyor indirectly). Optionally, a spacer 914 may be used to space the firstwall 910 a from the column 902 (e.g., to 1 inch, or greater). A secondspacer 920 may be placed between the first wall 910 a and the secondwall 912 a to provide a gap (for air, or for the addition of other fireresistant material or members) between the walls. The spacers 914, 920may also be constructed of plastic material, such as fiber-reinforcedcomposite material with fire retardant material.

As will be appreciated, utilizing double wall panels 800 for each of thetwo coplanar firewalls 910, 912, and spacing the walls 910, 912 apredetermined distance A from each other increases the fire resistancecharacteristics of the firewalls 900 a, 900 b, as opposed to using onlya single wall.

It will be understood that the firewall system as described herein isnot limited to use in cooling tower structures, but may be used in otherstructures or installations where it is desirable to contain one portionor area (e.g. cell) from another for fire containment or resistancepurposes.

It may be advantageous to set forth definitions of certain words andphrases that may be used within this patent document: the terms“include” and “comprise,” as well as derivatives thereof, mean inclusionwithout limitation; the term “or,” is inclusive, meaning and/or; thephrases “associated with” and “associated therewith,” as well asderivatives thereof, may mean to include, be included within,interconnect with, contain, be contained within, connect to or with,couple to or with, be communicable with, cooperate with, interleave,juxtapose, be proximate to, be bound to or with, have, have a propertyof, or the like. The term “couple” or “connect” refers to any direct orindirect connection between two or more components, unless specificallynoted that a direct coupling or direct connection is present.

Although the present invention and its advantages have been described inthe foregoing detailed description and illustrated in the accompanyingdrawings, it will be understood by those skilled in the art that theinvention is not limited to the embodiment(s) disclosed but is capableof numerous rearrangements, substitutions and modifications withoutdeparting from the spirit and scope of the invention as defined by theappended claims.

1-32. (canceled)
 33. A cooling tower comprising: a support frame structure defining an interior volume and including a first column and a second column; a fluid distribution system to distribute fluid within the interior volume defined by the support frame structure; a heat transfer material within the interior volume defined by the support frame structure and for receiving fluid from the fluid distribution system and through which the fluid travels; a fluid collection basin disposed beneath the support frame structure; air moving equipment operable for causing air movement for heat transfer between the fluid and air; and a firewall structure, the firewall structure comprising, a first wall panel and a second wall panel, each of the wall panels having a first wall spaced laterally from a second wall, and wherein the first wall panel and second wall panel are coupled to and extend between the first column and the second column, and the firewall structure separates a first area of the cooling tower from a second area of the cooling tower, and wherein the first and second columns provide load-bearing support for the cooling tower.
 34. The cooling tower in accordance with claim 33 wherein the first wall panel and the second wall panel each comprise plastic material and a fire retardant material.
 35. The cooling tower in accordance with claim 34 wherein the fire retardant material comprises brominated resin.
 36. The cooling tower in accordance with claim 33 wherein each of the first wall panel and the second wall panel comprise: a plurality of inner walls each extending between the first wall to the second wall and for connecting the first wall to the second wall.
 37. The cooling tower in accordance with claim 33 wherein the firewall structure further comprises: a first spacer disposed between the first wall panel and the first column; and a second spacer disposed between the second wall panel and the first column.
 38. The cooling tower in accordance with claim 37 wherein the first spacer and the second spacer each comprise fire retardant material.
 39. The cooling tower in accordance with claim 33 wherein the first wall is spaced about ¾ to about 2 inches laterally from the second wall in each of the wall panels.
 40. The cooling tower in accordance with claim 33 wherein the firewall structure further comprises: a first spacer disposed between the first wall panel and the second wall panel; and a second spacer disposed between the second wall panel and the first column.
 41. The cooling tower in accordance with claim 40 wherein the first spacer and the second spacer each comprise fire retardant material. a support frame structure defining an interior volume and having a first column and a second column;
 42. A cooling tower comprising: a support frame structure defining a first interior volume a second interior volume, and including a first column and a second column; a first cooling tower cell associated with the first interior volume and a second cooling tower cell associated with the second interior volume, each of the first and second cooling tower cells comprising, a fluid distribution system to distribute fluid within the respective interior volume defined by the support frame structure, a heat transfer material within the respective interior volume defined by the support frame structure and for receiving fluid from the fluid distribution system and through which the fluid travels, air moving equipment operable for causing air movement for heat transfer between the fluid and air; and a firewall structure, the firewall structure comprising, a first double wall panel member having a first outer wall spaced laterally from a second outer wall, a second double wall panel member having a first outer wall spaced laterally from a second outer wall, and wherein the first double wall panel member and the second double wall panel member are coupled to and extend substantially coplanar between the first column and the second column, and the firewall structure separates the first cooling tower cell from the second cooling tower cell.
 43. The cooling tower in accordance with claim 42 wherein the first double wall panel member and the second double wall panel member each comprise plastic material and a fire retardant material.
 44. The cooling tower in accordance with claim 43 wherein the fire retardant material comprises brominated resin.
 45. The cooling tower in accordance with claim 42 wherein each of the first double wall panel member and the second double wall panel member comprise: a plurality of inner walls each extending between the first outer wall to the second outer wall and for connecting the first outer wall to the second outer wall.
 46. The cooling tower in accordance with claim 42 wherein the firewall structure further comprises: a first spacer disposed between the first double wall panel member and the first column; and a second spacer disposed between the second double wall panel member and the first column.
 47. The cooling tower in accordance with claim 42 wherein the first outer wall is spaced about ¾ to about 2 inches laterally from the second outer wall in each of the double wall panel members.
 48. The cooling tower in accordance with claim 42 wherein the firewall structure further comprises: a first spacer disposed between the first double wall panel member and the second double wall panel member; and a second spacer disposed between the second double wall panel member and the first column.
 49. A firewall structure for use in a cooling tower having a support frame structure including a first column and a second column, the firewall structure comprising: a first double wall panel member having a first outer wall spaced laterally from a second outer wall, a second double wall panel member having a first outer wall spaced laterally from a second outer wall, and wherein the first double wall panel member and the second double wall panel member are coupled to and extend substantially coplanar between the first column and the second column, and the firewall structure separates the a first area of the cooling tower from a second area.
 50. The firewall structure in accordance with claim 49 wherein the first double wall panel member and the second double wall panel member each comprise plastic material and a fire retardant material.
 51. The firewall structure in accordance with claim 49 wherein each of the first double wall panel member and the second double wall panel member comprise: a plurality of inner walls each extending between the first outer wall to the second outer wall and for connecting the first outer wall to the second outer wall.
 52. The firewall structure in accordance with claim 49 wherein the firewall structure further comprises: a first spacer disposed between the first double wall panel member and the second double wall panel member; and a second spacer disposed between the second double wall panel member and the first column. 